EW Welder MANUAL Cover - Getec Inc Hydr. Welder MANUAL .pdf · General Information The HW series welder/generators “200-4, 225-4, 250-5.5, and 300-6” are welders that produce

OWNERS MANUAL

Hydraulically Driven Welders

Amps = 200-225-250-300

KW = 4 - 4.2 - 5.5 - 6

Phase = 1

RPM = 3600

AC Volt = 120/240

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General Information

The HW series welder/generators “200-4, 225-4, 250-5.5, and 300-6”

are welders that produce DC current welding power. The unit

consists of two major components; a DC welder and an AC

generator. The amperage of the DC welder is controlled by selector

switches. All HW DC welders are operating at 3600 RPM. The

generator section produces 120/240Volt and 60 Hz sine wave output

at 3600 RPM. The welder generator is equipped with a high volume

internal fan for a maximum cooling effect.

624 Harris Road

Ferndale, New York 12734

(845) 292-0800 (Phone)

(845) 292-0830 (Fax)

Manufacturer of high quality hydraulic generators and

welders

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Caution

When used with customer supplied flow

regulator, use extreme caution on initial

setup. Overspeed will cause physical

damage and is not covered under

manufacturer’s warranty.

624 Harris Road


(845) 292-0800 (Phone)

(845) 292-0830 (Fax)


welders

General Operating Instructions

This hydraulically-driven welder-generator consists of 3 main components :

a) hydraulic drive

b) DC welder

c) AC generator

For the welder or generator to function properly the hydraulic drive must maintain

the proper speed (3600 – 3720 for 60 Hz,3000-3120 for 50 Hz) under all

conditions. Always allow the set to run for at least 2 minutes before operating the

welder or generator.

Operation

1) Connect welder leads (observe polarity).

2) Set Range Switch to the highest position for startup3) Fine tune amp selector switch to desired amperge.

4) Start hydraulic system and turn Welder on(On Off Switch optional )

After waiting for a few minutes the welder is now ready for welding.

Increase amperage if necessary or decrease if amperage is too high.

Never operate any switches during welding.

The generator can be used during welding operation. A flicker and low Voltage in

the lights will occur every time you strike an arc, this cannot be avoided.

In order to obtain rated output of your generator section, the range switch must be

in the high position . The generator output is 120 VAC at 60

Hz and 230 V at 50 Hz. An optional 120/240 panel is available.

C:\my documents\Hydraulic Welder General Instructions.doc

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Hydra – Weld ™

General Installation

The Hydra-Weld™ is a hydraulically-driven AC welder/generator that will deliver rated amperage when

the proper flow is delivered to it’s hydraulic drive. Oil temperature should be between 100-140˚F. A

10-micron filter is also recommended to maintain the drive at its maximum performance. Depending on

the size of the reservoir, an oil cooler must be used; the smaller the reservoir; the larger the cooler.

The tank should NEVER be smaller than 2 times the required GPM.

When starting a new hydraulic system, we strongly recommend that you connect the pressure line to the

return, bypassing the hydraulic welder drive. You should operate the system for 10 minutes that way.

This will clean the system; otherwise, all kinds of problems will occur. After connecting the pressure

and return line to the welder’s hydraulic drive, state your system at a low speed, slowly increasing the

speed until you reached the proper operating speed. While setting up a hydraulically-driven welder or

generator, it is necessary to check the speed setting of the hydraulic drive, since most systems will vary

in many ways (temperature – flow – viscosity / type of oil – etc.) from our test set up.

NEVER allow the welder to exceed 3900 RPM.

The return line pressure, under no circumstances, should reach 100 PSI or seal failure will occur.

The case drain must be connected directly to the tank (do NOT connect to the return line). We strongly

recommend that the case drain be connected to the upper portion of the tank. Making it easier for the

case drain oil to return to the tank. Return line must be ¾ or larger.

624 Harris Road


(845) 292-0800 (Phone)

(845) 292-0830 (Fax)


welders (6/01)

Important Hydraulic

Circuit Installation

Information

If the hydraulically-driven welder/generator or

generator is mounted below the system tank, it is highly

recommended that a check valve with a very low cracking

pressure is installed in the case drain line (free flow motor

to tank, blocking tank to motor). This will eliminate seal

leakage during non-use time. It is also recommended that

the case drain be connected directly to the top of the tank

and not through a cooler or filter.

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200-4 Operating Instructions

This welder is a hydraulically driven welder and it is extremely important that

the hydraulic system can supply the proper flow and pressure to maintain a

welder speed of 3,600 RPM under load. If the welder drops below 3600 RPM,

it cannot perform properly.

Start Hydraulic system

Turn welder hydraulic system on

Allow welder 2-3 minutes for warm-up

Be sure the red light between the 2 AC receptacles is lit

This will show you that the welder is close to the roper RPM and that you

have AC generator output

Insert welding leads into welding receptacles

CAUTION – Be sure that the positive cable is in the positive receptacle and

the negative cable in the negative receptive.

Set Range Selector switch to the position that is in the amperage range you

need for your welding job. Then set the Amp Selector switch to the amperage

that is nearest your desired amperage. Begin to weld. You may have to

switch one position up or down to get the desired amperage.

NEVER MOVE ANY SWITCHES DURNING WELDING

624 Harris Road


(845) 292-0800 (Phone)

(845) 292-0830 (Fax)


welders

September 7, 2003

Page 2

Depending on the type rod you are using this welder is capable of welding

most 1/8 rod in some cases you can weld 5/32 rods.

The AC generator is capable of producing 4200 watts @ 120Volts and 60Hz.

The generator output is a sinewave output. For best performance on the

generator, the range selector switch must be in the generator position (Right).

The duty cycle on the welder is 45% @ a minimum and 65% @ ideal

conditions. The duty cycle on the generator is 100%. You can use both the

welder and the generator at the same time without any damage to this machine.

Depending on the amperage you are using the generator output will drop. As a

rule of thumb, both items welder and generator are using half of the

equipment. That means that if you are welding at full 200AMPS the generator

can produce very little. If you are welding at 100AMPS (50%) you have

about 2000 Watt of generator power available (50%).

Amp

selector

switch

Range

selector

switch

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250-5.5 Operating Instructions



















624 Harris Road


(845) 292-0800 (Phone)

(845) 292-0830 (Fax)


welders

October 6, 2003

Page 2














Amp Selector

Switch

Negative

Weld

Terminal

Range

Selector

Switch

Positive

Weld

Terminal

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250-5.5 Operating Instructions



















624 Harris Road


(845) 292-0800 (Phone)

(845) 292-0830 (Fax)


welders

October 6, 2003

Page 2














Negative

Weld

Terminal

Amp Selector

Switch Range

Selector

Switch

Positive

Weld

Terminal

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300-6 Welder-Generator Operations

1. Start Hydraulic System.

2. Allow system to operate for about 5 minutes before engaging welder-generator.

3. Engage welder-generator

3a. The red light between the receptacle must be lit bright indicating that the welder rotates at the proper

speed.

4. Set the range switch to the setting that covers the amperage you wish to weld at.

5. Set the amperage selector switch to the amperage that is closest to the amperage you want to weld at.

6. If the amperage is to high set the -10 amp switch to -10 amp side. This will lower the amperage by

10 amps from the amperage selector switch setting.

In order to maintain the set amperage welder must maintain its speed (3600 rpm). The max diameter rod

you can use on this welder is ¼” rod.

Do not change any switch settings during welding. The generator can be used during welding. To get the

6Kw at 120 volts from the generator the range switch must be in the 235-300 position.

The welder and generator are working as soon as the welder reaches the proper RPM (3600).

No switching is required when using the welder-generator.

300A - 6.0kVA

Model

6000 W att @ 120 VAC

Ferndale, New YorkUSA

624 Harris Road


(845) 292-0800 (Phone)

(845) 292-0830 (Fax)


welders

-10 amp switch

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Range

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September 7, 2003

Page 2

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GETEC Incorporated Telephone : (845)-292-0800

1107 Old Route 17 FAX # : (845)-292-0830

Ferndale, N.Y. 12734

Welder 200-300Page 1 of 2

Item # GETEC # Description 200 225 250 300

2 600933 Front Grid X X X X

3 600934 Front Shield B3/B14 X X X X

4 600935 Fan X X X X

5a 601237 Rotor 200 Amp X

5b 600936 Rotor 225-250 –300 Amp X X X

6 600937 Bearing X X X X

7a 601238 200 DC Weld Impedance X

7b 600938 225 DC Weld Impedance X

7c 601239 250 DC Weld Impedance X

7d 601240 300 DC Weld Impedance X

8 600939 Black top cover X X X X

9 600940 7 posit. Step Switch X X X X

10a 600941 Range Sw. (2 P) 200-225 X X

10b 601241 Range Sw. (3 P) 250-300 X X

11 600942 Step Switch knob X X X X

12 600943 Female 400A weld Term X X X X

13 600944 Male 400A weld Term X X X X

14a 601242 200 DC Panel X

14b 600945 225 DC panel X

14c 601243 250 DC Panel X

14d 601244 300 DC Panel X

15 600946 Welding rectifier bridge X X X X

16 600947 DC brush-holder w brushes X X X X

17 600958 Recep.Panel only X X X X

GETEC Incorporated Telephone : (845)-292-0800

1107 Old Route 17 FAX # : (845)-292-0830

Ferndale, N.Y. 12734

Welder 200-300Page 2 of 2

Item # Getec # Description 200 225 250 300

21 600949 Slip ring (51*22*08) X X X X

22 600950 Slip ring cover (dia 51) X X X X

23 600951 Varistor X X X X

24a 600952 Single-ph rectif. Bridge X X

24b 601245 Thee-Phase Rectf.Bridge X X X

26a 601246 Housing S & Stator 200 X

26b 600953 Housing L & Stator 225 X

26c 601247 Housing L & Stator 250 X

26d 601248 Housing L & Stator 300 X

27 600954 Stud M8x 30 X X X X

28 601249 Stay Bolt and Nut SM X

28 600955 Stay Bolt and Nut LG X X X

29 600956 Kit from J 609 to B314 X X X X

61 601175 Switch –10 Amp X X X X

63 600852 Swich On-Off X X X X

45 600922 Flowreg X X X X

43 600971 Coupling Set X X X X

42 600970 Motornount X X X X

46a 600975 Motor 200 X

46b 600972 Motor 225 X

46c 600972 Motor 250 X

46d 600972 Motor 300 X

47 600854 400 Amp Female Recept X X X X

19 600887 Louvered Panel X X X X

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. . . . . . . . . . . . . . . . . . . . . . . . . . . .Getec’s Web Page(Addition 1)

http://www.getecinc.com

August 14, 2001

Troubleshooting of HW

WELDERS

Welder Completely Dead – No AC or Weld

Power

Make sure welder is at proper speed=3600RPM. Unplug all external connections. A

shorted weld cable or generator accessory plugged in can cause the welder not to build

up. Several components can cause the welder to stop functioning completely. This is

mainly in the excitation circuit. Consisting of armature (rotor), excitations bridge (left

bottom corner) and auxiliary winding. Check the resistance of the auxiliary winding

by removing the two purple wires from the Excitation Bridge located at the left bottom

corner. The reading should be about 1.5ohms. Check the resistance of the armature

between the two slip rings – this should be 22ohms. Remove all wires for the left

bottom Rectifier Bridge and test for continuity between the terminals. Again, you

should get a high and low reading. If those three main components test out ok, try to

flash the armature with a 24volt circuit (previously explained how).

624 Harris Road


(845) 292-0800 (Phone)

(845) 292-0830 (Fax)


welders

.........




WELDER

No Output on Weld Receptacles or AC

Receptacles

This problem can be caused by many different factors. At rare occasions a

welder/generator could lose it’s residual magnetism, which will cause the welder to be

completely dead. To Re-energize the magnetism remove the receptacle panel. Locate

the 2 exciter bridges on bottom left and bottom right, pull off the red and black wire

coming from the brushes on the left bridge and red wire which is jumped over to the

right bottom bridge. With an OHM meter check the resistance between the red and

black wire which will check the resistance of the rotor, this should be about 25 ohms,

try to rotate the rotor while you take the reading to be sure the brushes are receded – if

the reading is intermitted check the resistance right on the slip rings. If necessary,

remove the brush holder. (See brushholder replacement). Apply 12Volts to the

terminals on the red and black wire coming from the brush holder. Apply 12 Volts for

about 5 seconds. Re-install wires – reinstall receptacle panel and louvered end cover

and start welding.

624 Harris Road


(845) 292-0800 (Phone)

(845) 292-0830 (Fax)


welders

.........




WELDERS

No Output on Weld Receptacles but AC

Receptacle Output OK

If you have no welding power at all but the AC (120volts) is fully operational, this could

be caused by three components

The welding impedance (transformer)

The stator windings

The main welding rectifier bridge

Using the electrical diagram check for continuity of the welding impedance. By

disconnecting the three heavy lead wires from the main welding bridge rectifier, you

can check continuity between those three wires. In any combination, the resistance

should be between one and 2 ohms. All three readings should be the same. If you have

readings that determines that the stator winding and impedance winding are in good

condition. With the three wires removed, you can now check the resistance of the main

Rectifier Bridge. By measuring resistance between the three terminals forward and

reverse you always should get a high and a low reading, for example; if you measure

between one and two, if the first reading is very high the reverse reading should be

very low. You also can check the bridge by taking a resistance reading on the main

welding terminals. Again, you should have a high and low reading by reversing the

leads.

624 Harris Road


(845) 292-0800 (Phone)

(845) 292-0830 (Fax)


welders

.........




WELDERS

No AC Output but Weld Output

If the welder section functions properly but you have no AC output remove the

receptacle panel and make sure the white plugs are plugged solid. If there are

connected all the way, disconnect and make a resistance reading as follows

Blue to Brown (1.2ohm)

Black to White (1.2ohms)

If either one of those two readings is open the AC windings are defective. If they both

check out ok, check the receptacle and the wires going to the receptacles. To be certain

that is in the receptacle panel wiring, very carefully startup the welder and check for

120 volts between Blue and Brown and again 120 Volts between Black and White. If

you have 120 Volts pressing at those two readings, you must have a defective receptacle

or receptacle wiring.

624 Harris Road


(845) 292-0800 (Phone)

(845) 292-0830 (Fax)


welders

.........




WELDERS

Low Welding Amps

Low welding amps can be caused by three components

A defective Excitation Bridge located on the bottom right hand corner

B an open fine control (Optional). Resistance should be 6 ohms.

C Thermal trip in the windings. Disconnect the two AC wires off the bottom right

hand Excitation Bridge (white&orange) and make a resistance reading. With the

seven-step selector switch in the lowest position and the range switch and in the high

position you should get about 2 ohms. Move the seven-step switch while observing the

ohmmeter all the way to its highest position. The resistance should increase slightly

with every step. You should end up with about 3 ohms. If you do not start off with 2

ohms and the circuit shows open move your ohm meter 1 lead to the center terminal on

the range switch, the other ohm meter lead onto the terminal RL1 on the seven position

switch. If you have a reading, there about 2ohms the transformer is ok. To test for the

terimal trip in a windings take a reading between the center post of the range switch

and the white wire you remove from the Excitation Bridge. You should get 0ohms.

Any other readings on the trip is defective. To check the fine control put one-ohm

meter lead on the seven-step switch terminal RL1, the other lead on the orange wire

you removed from the Excitation Bridge. You should be able by moving the fine

control up and down adjust the ohmmeter reading between 0 and 6 ohms. To check

the Excitation Bridge, remove all wires from it and measure forward and backward

going around clockwise. In any position and in any combination between terminals

you should get a high and low reading. If any of the readings come out the same, the

bridge is defective.

624 Harris Road


(845) 292-0800 (Phone)

(845) 292-0830 (Fax)


welders

.........




WELDERS

Intermitting Welder Operation

Welder works properly for a few minutes and then stop operating but returns to full

welding power after several minutes of cooling off.

This will occur when the welder is operated past its duty cycle or in extreme high

ambient temperatures or if welder-cooling circuit is blocked. Be sure air intake is free

welder cooling might be affected by engine heat. Allow fresh air to enter louvered end

cover on welder. A cooling off period is 4-5 times longer if welder is turned off and

sitting still. Running it at its RPM will speed up the cooling and reset the internal

thermal trip.

624 Harris Road


(845) 292-0800 (Phone)

(845) 292-0830 (Fax)


welders

.........



Disassembly of HW WELDER

Rotor Replacement

Remove two each fan grids. Remove receptacle panel Remove brush holder

held with one screw. Remove four plastic stop nuts holding front shield (fan

housing)

With gear puller push out rotor from slip ring side. Remove rotor assembly

from stator. Remove snap ring from shaft end which had the Pulley on it. Push

rotor out of front shield. Examine bearing and front shield to be sure it does not

need to be replaced. Push new rotor into front shield. Re-install small snap

ring. Be sure snap ring is in grove. Carefully re-install rotor into stator. Use

rubber mallet to tap into place. Re-install four elastic stop nuts. Tighten elastic

stop nuts in a cris/cross manner. Turn rotor by hand to make sure it turns

freely. If rotor seems not to run freely, tap the casting with a small metal

hammer on the slip ring end casting. This will seat the bearing. Apply 12Volts

to the slip ring for about 20 seconds. This will make sure that the residual

magnetism is energized. Re-install the brush holder. Be sure to have the

insulator behind the brush holder. Check for brush alignment to slipring. Re-

install the two fan grids. re -install receptacle panel or louvered panel on slip

ring end.

624 Harris Road


(845) 292-0800 (Phone)

(845) 292-0830 (Fax)


welders

.........



Disassembly of HW WELDER

Replace Brushes

Remove receptacle panel

Cut tie raps holding brush holder wires, red & black

Unplug red & black from rectifier bridges.

Install wires in same way with new brush holder – red to red and black to black

Remove old brush holder by removing one screw holding brush holder

Do not lose plastic insulator located behind the brush holder

Check sliprings

Clean and polish with very fine sandpaper

Check resistance of rotor (armature) on sliprings

Reading should be a 25 ohms ±3 ohm

Install new brush holder with brushes. Make sure brush holder is seated (dimple in

casting)

Check brush to be on sliprings.

Install tie rap’s to hold wires

Check resistance of rotor (armature) on sliprings

Reading should be a 25 ohms ±3 ohm

624 Harris Road


(845) 292-0800 (Phone)

(845) 292-0830 (Fax)


welders

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Documents

EW Welder MANUAL Cover - Getec Inc Hydr. Welder MANUAL .pdf · General Information The HW series welder/generators “200-4, 225-4, 250-5.5, and 300-6” are welders that produce